Mower cord and manufacturing method for mower cord

ABSTRACT

The present invention relates to a manufacturing method for a mower cord and includes pressing a resin wire rod and plastically deforming at least part of the wire rod in an axis perpendicular direction. Work-hardening of a surface of the plastically deformed portion allows dramatic enhancement of mowing efficiency.

TECHNICAL FIELD

The present invention relates to a mower cord or the like used in a cordtype mowing apparatus.

BACKGROUND ART

There has recently been known a nylon cord which is used while beingattached to an outer periphery of a rotating component, such as a disc,in a mowing apparatus (see, for example, Japanese Patent Laid-Open No.2007-135418). The nylon cord cuts away grass while whirling due torotation of the rotating component and is coming into widespread useinstead of a metallic rotary blade. The nylon cord is not sharp incomparison with a metallic rotary blade, and even contact of a humanbody with the whirling nylon cord is unlikely to result in seriousinjury. The nylon cord can be replaced in accordance with the extent ofbreakage or abrasion and is easy to replace.

To improve the mowing capability of such a nylon cord, the idea ofmaking a cross-section in an axis perpendicular direction (a transversesection) quadrangular or rhombic, or the idea of forming uneven portionsin a longitudinal direction in a cross-section in an axis direction (alongitudinal section) has been proposed (see, for example, JapanesePatent Laid-Open No. 2003-230312). With this configuration, a nylon cordis likely to bite into grass and has the enhanced effect of cuttinggrass.

Note that a nylon cord may break and scatter or may become unnecessaryafter replacement and be discarded, and may be left there. In this case,the nylon cord does not decompose spontaneously and is almostpermanently left. Under the circumstances, use of a cord made ofbiodegradable plastic that decomposes spontaneously instead of a nyloncord is proposed from the viewpoint of environmental conservation (see,for example, Japanese Patent Laid-Open No. 2012-0191913).

SUMMARY OF INVENTION Technical Problem

A nylon cord is manufactured by extruding and molding a resin rawmaterial and then stretching the material. To make a transverse sectionquadrangular or rhombic, the shape of a hole of a die at the time ofextrusion molding may be made quadrangular or rhombic. However, unevenportions continuous in a longitudinal direction of the cord cannot beformed in the extrusion-molding step and the stretching step.

To form uneven portions in the longitudinal direction of the nylon cord,the cord after stretching needs to be sheared such that the cord ispartially notched. The strength of a notched portion of the corddecreases and is prone to breakage. Additionally, uneven portions arelikely to abrade during mowing.

Assume a case where a rod-like member having uneven portions in alongitudinal direction is directly made using an injection die and isused as a mower cord. Since the cord has not undergone stretching and isinsufficient in elasticity and strength, the cord is useless as a mowercord.

A cord manufactured using biodegradable plastic is likely to have lowerrigidity (i.e., softer) than a normal nylon cord. A mower cord beats andcuts grass during rotation and is required to have a given degree ofrigidity. If biodegradable plastic is used as the material for the mowercord, there is fear that mowing efficiency decreases somewhat. If unevenportions are formed at a cord manufactured using biodegradable plasticthrough shearing, the cord is likely to have even lower strength.

The present invention has been made in view of the above-describedproblems, and has as its object to provide a mower cord capable ofdramatically enhancing mowing efficiency.

Solution to Problem

According to the present invention that attains the above-describedobject, there is provided a manufacturing method for a mower cord,including pressing a resin wire rod and plastically deforming at leastpart of the wire rod in an axis perpendicular direction.

In connection with the above-described manufacturing method, across-sectional shape of the wire rod may be changed to an imperfectcircular shape by the plastically deforming.

In connection with the above-described manufacturing method, a sitewhere the at least part of the wire rod is plastically deformed may havea flat portion which is thinner in a pressing direction than the wirerod before the pressing.

In connection with the above-described manufacturing method, the sitewhere the at least part of the wire rod is plastically deformed may havean extended portion which expands on an outer side in a radial directionof the wire rod before the pressing.

In connection with the above-described manufacturing method, an outeredge in the radial direction of the flat portion or the extended portionmay have a ridge which extends in a longitudinal direction of the wirerod.

In connection with the above-described manufacturing method, a pluralityof uneven portions which are continuous in the longitudinal direction ofthe wire rod may be formed at the site where the at least part of thewire rod is plastically deformed.

In connection with the above-described manufacturing method, the unevenportions may be formed by trimming off part of the plastically deformedsite.

In connection with the above-described manufacturing method, the wirerod may be made by stretching a resin material.

In connection with the above-described manufacturing method, across-section in the axis perpendicular direction of the wire rod mayhave any one of a circular shape, an elliptical shape, a rectangularshape, and a rhombic shape.

In connection with the above-described manufacturing method, the atleast part of the wire rod may be plastically deformed by pressing thewire rod with a pressure die.

In connection with the above-described manufacturing method, thepressure die may have a groove which stores the wire rod, and the wirerod may be pressed while the wire rod is held by the groove.

In connection with the above-described manufacturing method, the groovemay come into contact with a place on an inner side in a width directionof the wire rod.

In connection with the above-described manufacturing method, thepressure die may have pressing surfaces which are continuous on outersides in the width direction of the groove, and the wire rod may bepressed by the pressing surfaces while the wire rod is held by thegroove.

In connection with the above-described manufacturing method, thepressure die may have a tapered surface which comes into contact withthe wire rod.

According to the present invention that attains the above-describedobject, there is provided a mower cord manufactured by any one of theabove-described manufacturing methods.

According to the present invention that attains the above-describedobject, there is provided a mower cord including a cord-like main bodyportion, and flat portions which are continuous on outer sides in aradial direction of the main body portion and are molded to be thinnerthan the main body portion through plastic deformation.

In connection with the above-described mower cord, a plurality of unevenportions may be provided along a longitudinal direction of the main bodyportion by the flat portions.

In connection with the above-described mower cord, the uneven portionsmay be formed by trimming off part of the flat portions.

In connection with the above-described mower cord, surfaces of the flatportions may be harder than a surface of the main body portion.

In connection with the above-described mower cord, the main body portionmay be obtained by stretching a resin material.

In connection with the above-described mower cord, a cross-section in anaxis perpendicular direction of the main body portion may have any oneof a circular shape, an elliptical shape, a rectangular shape, and arhombic shape.

In connection with the above-described mower cord, the mower cord may bemade of biodegradable resin.

In connection with the above-described mower cord, glass wool may bemixed in the mower cord.

Advantageous Effect of Invention

The present invention allows dramatic enhancement of mowing efficiency.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1(A) is a partial perspective view showing part of a mower cordaccording to the present invention, and FIG. 1(B) is a partial plan viewof the cord.

FIG. 2 is a flowchart showing a production process for the mower cord.

FIG. 3 is a plan view showing the configuration of a die used forproduction of the mower cord.

FIG. 4(A) is a cross-sectional view of the die taken along line A-A inFIG. 3, and FIG. 4(B) is a cross-sectional view of the die taken alongline B-B in FIG. 3.

FIG. 5(A) is a side view showing the configuration of the die, and FIG.5(B) is a side cross-sectional view.

FIG. 6(A) is a front cross-sectional view showing the states of the dieand the mower cord before plastic working, FIG. 6(B) is a frontcross-sectional view showing the states of the die and the mower cordafter plastic working, and FIG. 6(C) is a front cross-sectional view ofthe mower cord after completion of a plastic-working step.

FIG. 7(A) is a front cross-sectional view showing the states of the dieand the mower cord before trimming, and FIG. 7(B) is a frontcross-sectional view showing the states of the die and the mower cordafter trimming.

FIG. 8 is a usage state view showing a state in which the mower cord isattached to a mowing apparatus.

FIGS. 9(A) to 9(D) are front cross-sectional views showing otherexamples of the die and the mower cord.

FIGS. 10(A) to 10(D) are front cross-sectional views showing otherexamples of the die and the mower cord.

FIGS. 11(A) and 11(B) are front cross-sectional views showing anotherexample of the die.

FIGS. 12(A) and 12(B) are front cross-sectional views showing anotherexample of the die.

FIG. 13(A) is a plan view showing another example of the die, FIG. 13(B)is a plan partial cross-sectional view, FIG. 13(C) is a frontcross-sectional view taken along line C-C in FIG. 13(A), and FIG. 13(D)is a front cross-sectional view taken along line D-D in FIG. 13(A).

FIGS. 14(A) to 14(C) are front cross-sectional views showing an aspectin which the mower cord is plastically deformed in a cross-section inFIG. 13(C), and FIGS. 14(D) to 14(F) are front cross-sectional viewsshowing an aspect in which the mower cord is plastically deformed in across-section in FIG. 13(D).

FIG. 15 is a plan view showing other examples of the die and the mowercord.

FIGS. 16(A) and 16(B) are front cross-sectional views taken along lineA-A in FIG. 15.

FIGS. 17(A) to 17(C) are plan views showing other examples of the mowercord.

FIGS. 18(A), 18(B), and 18(C) are a front cross-sectional view, a planview, and a side view, respectively, showing another example of themower cord.

DESCRIPTION OF EMBODIMENT

A mower cord according to the present invention will be described belowin detail with reference to the drawings.

A mower cord 10 shown in FIG. 1 is used to mow not only grass, such as alawn, ridge grass, and weeds, but also various plants and trees, such asbamboo grass and twigs. The material for the mower cord 10 is, forexample, resin, and a monofilament of synthetic resin is arepresentative example.

The mower cord 10 includes a cord-like main body portion 12 and flatportions 14 which are obtained through plastic deformation and arethinner than the main body portion 12. The flat portion 14 is flatterthan a wire rod S (see FIG. 2) before plastic deformation of the mowercord 10. Note that the flat portion 14 can also be defined as anextended portion which is expanded and formed so as to protrude from themain body portion 12 toward an outer side in a radial direction. Thecross-sectional shape in an axis perpendicular direction of the mowercord 10 is changed to an imperfect circular shape by the plasticdeformation.

The wire rod S is obtained by stretching a resin material. The materialfor the wire rod S is obtained by, e.g., melt-spinning and stretching apolyamide, such as nylon 6, nylon 66, nylon 610, or nylon 11, apolyester, such as polyethylene terephthalate or polybutyleneterephthalate, a polyolefin, such as polyethylene or polypropylene, apolyhalogenated hydrocarbon, such as polyvinylidene chloride, polyether,or one of copolymers based thereon. A biodegradable plastic, such aspolylactic acid, polycaprolactone, polyhydroxyalkanoate, polyglycolicacid, modified polyvinyl alcohol, casein, modified starch, or a PETcopolymer, can also be used as a preferred material. If a biodegradableplastic is stretched into the form of a cord, the cord is likely to haveinsufficient elasticity, and mowing efficiency is likely to decrease.The mowing efficiency is enhanced by work-hardening a surface throughplastic deformation and forming uneven portions, as will be describedlater. This allows compensation for shortcomings of the material. It ispreferable to improve properties, such as abrasion resistance, by mixingglass wool into one of the above-described raw materials.

The main body portion 12 has a circular or elliptical cross-section,which is close to an elliptical shape here. The main body portion 12 isobtained by applying pressure on the wire rod S perfectly circular incross-section to plastically deform the wire rod S into an ellipticalshape. A thickness (height) X1 in a pressure-application direction X ofthe main body portion 12 is about 3 mm, and a thickness (width) Y1 in adirection (a pressure-application perpendicular direction Y)perpendicular to the pressure-application direction X and a longitudinaldirection Z is about 3 mm. Each flat portion 14 protrudes in thepressure-application perpendicular direction Y from the main bodyportion 12, a thickness (blade thickness) X2 in the pressure-applicationdirection X is about 1 mm, and a thickness (blade width) Y2 in thepressure-application perpendicular direction Y is about 1.5 mm. Thus,the flat portion 14 is smaller than the main body portion 12 in thethickness in the pressure-application direction X. The amount of plasticdeformation in the pressure-application direction X at the flat portion14 with respect to the wire rod S is preferably about 40% to 95%, morepreferably about 40% to 80%. After sufficient plastic deformation tothis extent, the shape is unlikely to be restored to the original shapeof the wire rod S.

One pair of flat portions 14 is formed so as to be arranged on two outersides in the pressure-application perpendicular direction Y of the mainbody portion 12. As a result, a full width YA in thepressure-application perpendicular direction of the mower cord 10 isabout 5 mm. Note that various dimensions are illustrative only and canbe appropriately set depending on the intended use. For example, a fullthickness in the pressure-application direction X of the mower cord 10is preferably not less than 1.2 mm and not more than 4 mm, morepreferably not more than 3 mm. A full thickness in the neighborhood of1.6 mm is suitable for a lawn, and a full thickness not less than 2.0 mmand not more than 2.6 mm is suitable for ridge grass and weeds infarmland or on the roadside. A full thickness not less than 2.4 mm andnot more than 4 mm is particularly preferable for ridge grass and weeds,and a full thickness of about 2.4 mm to 3 mm is more preferable. Thelength of the mower cord 10 is, for example, 200 mm and can be setdepending on the intended use. The mower cord 10 several meters toseveral tens of meters long may be cut and used.

Although the details will be described later, the flat portion 14 is asite formed by significantly plastically deforming the wire rod S. Asurface of the flat portion 14 is generally harder than a surface of themain body portion 12 due to, e.g., accumulation of internal strain.

A plurality of uneven portions 16 are formed along the longitudinaldirection Z of the main body portion 12 at the flat portions 14. Eachuneven portion 16 is an arc-shaped cut, and the uneven portions 16 arecontinuous in the longitudinal direction Z at predetermined unevenportion intervals P. The uneven portions 16 are formed by trimming(shearing) the flat portions 14 with a punch or the like.

A production process for the mower cord 10 will be described withreference to FIG. 2. FIG. 2 is a flowchart showing the manufacturingprocess for the mower cord 10.

The production process for the mower cord 10 includes a stirring step(step S100), an extrusion-molding step (step S101), a cooling step (stepS102), a stretching step (step S103), a heat treatment step (step S104),a winding step (step S105), a softening process step (step S106), adrying process step (step S107), a plastic-working step (step S108), atrimming step (step S109), and a performance check step (step S110), anda final working step (step S111).

First, in the stirring step (step S100), a raw material inside a vesselis stirred. The stirred raw material is extruded through a die and ismolded into the form of a string in the extrusion-molding step (stepS101). The object molded in the form of a string is cooled in a coolingbath in the cooling step (step S102). The cooled object is stretched inthe stretching step (step S103). The stretched object is heated in theheat treatment step (step S104). The heated object is wound around ashaft center in the winding step (step S105). The object wound aroundthe shaft center is dipped in a plasticizer and subjected to softeningin the softening process step (step S106). The object subjected to thesoftening is heated and subjected to drying in the drying process step(step S107). The object subjected to the drying serves as the wire rodS. In the plastic-working step (step S108), the wire rod S isplastically deformed through press working using a pressure die to formthe main body portion 12 and the flat portions 14. In the trimming step(step S109), the uneven portions 16 are formed at the flat portions 14by a punch. After that, in the performance check step (step S110), theobject is subjected to a performance check on strength, dimensions, andthe like. The object subjected to the performance check is made into themower cord 10 as a product by, e.g., cutting the object to a desiredlength in the final working step (step S111). Note that the stretchingstep (step S103) and the heat treatment step (step S104) may beappropriately repeated a plurality of times before the winding step(step S105). Note that the material can be further hardened throughrapid heating after the plastic-working step (step S108).

A working apparatus 200 used in the plastic-working step (step S108) andthe trimming step (step S109) will be described with reference to FIGS.3 to 5.

FIGS. 3 to 5 show a die 210 which is set in a press machine of theworking apparatus 200. The die 210 has a first pressure die 220, asecond pressure die 230, and a plurality of (two here) punches 240. Thedie 210 applies pressure on the wire rod S while holding the wire rod Ssandwiched between the first pressure die 220 and the second pressuredie 230, thereby plastically deforming at least part of the wire rod Sand forming the flat portions 14. The uneven portions 16 are formed bytrimming part of the flat portions 14 of the wire rod S with the punches240. As shown in FIG. 3, in the die 210, a region where part of the wirerod S is to be plastically deformed is defined as a plastic-workingregion 210A while a region where trimming by the punches 240 is to beperformed is defined as a trimming region 210B.

As shown in FIG. 4, the first pressure die 220 has a groove 222 whichstores at least part of the wire rod S, one pair of pressing surfaces224 which are continuous on two outer sides in a width direction (thepressure-application perpendicular direction Y) of the groove 222, andsliding holes 228, in which the punches 240 slide along thepressure-application direction X.

The groove 222 primarily holds the wire rod S by storing part of thewire rod S such that the wire rod S does not move at the time ofpressure application in a sandwiched state. Of course, the groove 222can also plastically deform the wire rod S. A maximum width Mw in thepressure-application perpendicular direction Y of the groove 222 is setto be smaller than a maximum width Sw (see FIG. 6) of the wire rod S inthe pressure-application perpendicular direction Y. Contact points,contact lines, or contact surfaces (contact lines 222A or contactsurfaces 222B (see FIG. 6) in the present embodiment) at which thegroove 222 is to come into contact with the wire rod S are set on aninner side in a width direction (defined as the pressure-applicationperpendicular direction Y) of the wire rod S.

The groove 222 of the first pressure die 220 has tapered surfaces whichtilt with respect to the pressing direction X at portions which are tocome into contact with the wire rod S. That is, the contact surfaces222B of the groove 222 serve as tapered surfaces (see FIG. 6) which tiltat an angle α with respect to the pressing direction X. In the presentembodiment, the groove 222 has one pair of contact surfaces 222B, whichare both tapered surfaces. The groove 222 has a V-shape. As shown inFIG. 4(B), a distance between the one pair of contact surfaces 222B inthe pressure-application perpendicular direction Y is larger on thepressing side (e.g., M1) in the pressing direction X and is smaller onthe side (e.g., M2) opposite to the pressing side in the pressingdirection X. By holding the wire rod S with the one pair of taperedsurfaces, as described above, an axis of the wire rod S can be centeredalong the longitudinal direction Z. Since the wire rod S inevitablybends in the stretching step and the like, working accuracy can besignificantly enhanced by plastically deforming the wire rod S whileperforming centering.

The pressing surfaces 224 arranged on two sides of the groove 222 tiltat an angle of β with respect to the pressing direction X (see FIG. 6),and the angle β is larger than the angle α of the contact surfaces 222Bof the groove 222. Note that, in the present embodiment, the angle β is90° and that the pressing surfaces 224 are flat surfaces perpendicularto the pressing direction X. The pressing surfaces 224 plasticallydeform the element wire S such that part of the element wire S iscrushed to form the flat portions 14. As a result, the flat portions 14are flat plates perpendicular to the pressing direction X.

The second pressure die 230 has a groove 232 which stores at least partof the wire rod S, one pair of pressing surfaces 234 which arecontinuous on two outer sides in a width direction (thepressure-application perpendicular direction Y) of the groove 232, andsliding holes 238, in which the punches 240 slide along thepressure-application direction X.

The groove 232 holds the wire rod S by storing part of the wire rod Ssuch that the wire rod S does not move at the time of pressureapplication in a sandwiched state and plastically deforms the wire rodS. The maximum width Mw in the pressure-application perpendiculardirection Y of the groove 232 is set to be smaller than the maximumwidth Sw (see FIG. 6) of the wire rod S in the pressure-applicationperpendicular direction Y. Contact points, contact lines, or contactsurfaces (contact lines 232A or contact surfaces 232B in the presentembodiment) at which the groove 232 is to come into contact with thewire rod S are set on the inner side in the width direction (thepressure-application perpendicular direction Y) of the wire rod S.

Additionally, the groove 232 of the second pressure die 230 has taperedsurfaces which tilt with respect to the pressing direction X at portionswhich are to come into contact with the wire rod S. That is, the contactsurfaces 232B of the groove 232 serve as tapered surfaces which tilt atthe angle α with respect to the pressing direction X (see FIG. 6). Inthe present embodiment, the groove 232 has one pair of contact surfaces232B, which are both tapered surfaces. The groove 222 has a V-shape. Asshown in FIG. 4(B), a distance between the one pair of contact surfaces232B in the pressure-application perpendicular direction Y is larger onthe pressing side (e.g., M1) in the pressing direction X and is smalleron the side (e.g., M2) opposite to the pressing side in the pressingdirection X. By holding the wire rod S with the one pair of taperedsurfaces, as described above, the axis of the wire rod S can be centeredalong the longitudinal direction Z. Since the wire rod S inevitablybends in the stretching step and the like, working accuracy can besignificantly enhanced by plastically deforming the wire rod S whileperforming centering.

The pressing surfaces 234 arranged on two sides of the groove 232 tiltat the angle β with respect to the pressing direction X (see FIG. 6),and the angle β is larger than the angle α of the contact surfaces 232Bof the groove 232. Note that, in the present embodiment, the angle β is90° and that the pressing surface 234 are flat surfaces perpendicular tothe pressing direction X. The pressing surfaces 234 plastically deformthe element wire S such that part of the element wire S is crushed toform the flat portions 14.

Note that although the grooves 222 and 232 of the first pressure die 220and the second pressure die 230 are configured to have similar shapes inthe present embodiment, the present invention is not limited to this.For example, one of the pressure dies 220 and 230 may have a flatsurface.

The punches 240 are installed in the respective sliding holes 228 of thefirst pressure die 220 and are reciprocable in the pressure-applicationdirection X. When each punch 240 moves toward the second pressure die220, a distal end of the punch 240 enters into the sliding hole 238 ofthe second pressure punch 240 (see FIG. 7). With intersection of thedistal end of the punch 240 and the sliding hole 238, part of the flatportion 14 of the element wire S is sheared. Since the punch 240 has acylindrical shape, the uneven portion 16 to be formed at the flatportion 14 has an arcuate shape. The one pair of punches 240 is arrangedon the two outer sides of the grooves 222 and 223 with an intervaltherebetween. As shown in FIG. 3, a distance F between inner sides ofthe one pair of punches 240 is set to be equal to or more than themaximum widths Mw of the grooves 222 and 232 and be less than the widthSw of the wire rod S. The punches 240 as one pair are shifted from eachother by a half uneven portion interval (0.5 P) in the longitudinaldirection Z.

As a result, if the one pair of extended portions 12 is sheared with theone pair of punches 240 while movement in the longitudinal direction Zof the wire rod S over a distance corresponding to the uneven portioninterval P is repeated, the uneven portions 16 are formed at the unevenportion intervals P at each flat portion 14, as shown in FIG. 3. Theuneven portions 16 of one flat portion 14 can be shifted in the phase inthe longitudinal direction Z by the half uneven portion interval of 0.5P from those of the other flat portion 14. The shift of the unevenportions 16 of the one flat portion 14 in the phase in the longitudinaldirection Z by the half uneven portion interval of 0.5 P from those ofthe other flat portion 14 allows avoidance of a local constriction andenhances the strength. Note that the feed of the wire rod S can beincreased by arranging a plurality of punches 240 in the longitudinaldirection Z or devising the distal end shape of the punch such that asingle punch can form a plurality of uneven portions 16.

A plastic-working method and a trimming method for the wire rod S usingthe working apparatus 200 will be described.

When the wire rod S is inserted into the plastic-working region 210A ofthe grooves 222 and 232 of the die 210, and the first pressure die 220and the second pressure die 230 of the die 210 are brought closer by thepress machine (not shown), the wire rod S is held by the grooves 222 and232, as shown in FIG. 6(A). At this time, the one pair of contactsurfaces 222B and the one pair of contact surfaces 232B of the grooves222 and 232 each serve as tapered surfaces which tilt to have a V-shapedcross-section, and the wire rod S is centered along the longitudinaldirection Z. Since the maximum widths Mw of the grooves 222 and 232 aresmaller than the maximum width S2 of the wire rod S, part of the wirerod S protrudes from the grooves 222 and 232 in the width direction.

When the first pressure die 220 and the second pressure die 230 arefurther brought closer in this state, part of side surfaces of the wirerod S is crushed by the pressing surfaces 224 and 234 and is expandedand stretched in the pressure-application perpendicular direction Ywhile the wire rod S is compressed by the grooves 222 and 232, as shownin FIG. 6(B). If the pressure application is repeated each time theelement wire S is moved in the longitudinal direction Z over thedistance corresponding to the interval P, as shown in FIG. 3, a regionheld by the grooves 222 and 232 (which may be plastically deformed) ofthe wire rod S serves as the main body portion 12, and regionsplastically deformed under pressure from the pressing surfaces 224 and234 serve as the flat portions 14, as shown in FIG. 6(C). The main bodyportion 12 has a perfect circular shape or an elliptical shape, and theflat portions 14 are in the form of a plate.

At the same time, in the trimming region 210B, the punches 240 move upand down while the first pressure die 220 and the second pressure die230 are close to each other, i.e., while the element wire S is held andcentered by the grooves 222 and 232, as shown in FIGS. 7(A) and 7(B). Asa result, an arc-shaped cut is made in each flat portion 14 to form theuneven portion 16, and a cut piece 16A drops through the sliding hole238. By repeating the trimming each time the element wire S is movedover the distance corresponding to the uneven portion interval P, theplurality of uneven portions 16 of the flat portions 14 are formed.

A mowing apparatus 20, to which the mower cord 10 is attached, will bedescribed with reference to FIG. 8. FIG. 8 shows a state in which themower cord 10 is attached to the mowing apparatus 20. The mowingapparatus 20 includes a handle 21 as a grip portion, a shaft 22, aproximal end portion of which is attached to the handle 21, a disc 23which is rotatably attached to a distal end portion of the shaft 22, apower source (not shown), such as a motor, which rotates the disc 23,and the like. One or a plurality of mower cords 10 are replaceablyattached to an outer periphery of the disc 23. The mower cords 10 whirldue to rotation of the disc 23 and cut away grass.

As described above, the mower cord 10 according to the presentembodiment includes the cord-like main body portion 12, and the flatportions 14 that are expanded and formed on outer sides in the radialdirection of the main body portion 12 through plastic deformation. Withthe plastic deformation, a cross-sectional shape is changed to animperfect circular shape, and the mower cord 10 is likely to bite intograss. Since the flat portions 14 are level, the flat portions 14function as so-called blade edges and are likely to bite into grass.Grass can be efficiently cut. Additionally, a surface of each flatportion 14 can be hardened through cold (room temperature) plasticworking. As a result, cutting efficiency can be further enhanced, andabrasion resistance enhances at the same time. This allows an increasein the service life of the mower cord 10.

In addition, in the mower cord 10, a plurality of uneven portions 16 areformed along the longitudinal direction Z by trimming off part of theflat portions 14. As a result, the uneven portions 16 catch on grass andcan cut grass like a so-called saw blade. Since the uneven portions 16are formed by trimming off, through shearing, the flat portions 14 thatare surface-hardened through plastic deformation in the presentembodiment, a cross-section of each uneven portion 16 is also hard andis likely to bite into grass. Since the uneven portions 16 serving as apseudo saw blade are thin, extremely high efficient mowing can beimplemented.

The amount of plastic deformation of the main body portion 12 is smallerthan those of the flat portions 14, and the main body portion 12 canmaintain original flexibility of a stretched element wire.Advantageously, the volume of each surface-hardened flat portion 14 issmaller than that of the main body portion 12. As a result, the whole ofthe mower cord 10 can ensure appropriate pliability without breaking orfracturing, and the uneven portions 16 (a blade edge) can be locallyhardened. This allows implementation of both an increase in service lifeand improvement in mowing efficiency.

In the manufacturing method according to the present embodiment, sincethe first and second pressure dies 220 and 230 apply pressure on thewire rod S while the grooves 222 and 232 hold the wire rod S, the formaccuracy of plastic deformation can be enhanced. Additionally, contactpoints, contact lines, or contact surfaces, at which the grooves 222 and232 are to come into contact with the wire rod S, are set on the innerside in the width direction of the wire rod S. If pressure is applied onthe wire rod S at the contact points, the contact lines, or the contactsurfaces, the wire rod S is pushed and spread in thepressure-application perpendicular direction Y. Thus, part of the wirerod S can flow in the pressure-application perpendicular direction Y andmove toward the flat portions 14.

In addition, portions (i.e., the contact surfaces 222B and 232B of thegrooves 222 and 232) which are to come into contact with the wire rod Sof the pressure dies 220 and 230 serve as tapered surfaces which tiltwith respect to the pressing direction, and the wire rod S underpressure force is automatically centered. This allows furtherenhancement of the form accuracy of the mower cord 10. The pressure dies220 and 230 have the pressing surfaces 224 and 234 that are continuouson the outer sides in the width directions of the grooves 222 and 232.Since part of the wire rod S can be pressed by the pressing surfaces 224and 234 while the wire rod S is held by the grooves 222 and 232, theflat portions 14 can be cold-worked (at room temperature) to be thinnerthan the main body portion 12 by the pressing surfaces 224 and 234 whilethe main body portion 12 is kept thick by the grooves 222 and 232.

In the present embodiment, the cross-sectional shape of the wire rod Sis a perfect circular shape. At the time of manufacture of the wire rodS, a twist may generally appear. In the case of a perfect circularshape, the wire rod S can be plastically deformed without straighteningthe twist. That is, the wire rod S in a twisted state is plasticallydeformed. As a result, the wire rod S can avoid being affected by thetwist.

In the present embodiment, the plastic-working step (step S108) and thetrimming step (step S109) are continuously performed without inserting awinding step therebetween. This facilitates positioning when the punches240 form the uneven portions 16 at the flat portions 14. Since the firstpressure die is integral with the punches in the present embodiment,positioning accuracy can be further enhanced.

Note that in the case of a conventional manufacturing method as areference that lets a material pass through a die having a rhombic holewhile performing temperature control such that the material has fluidityin extrusion-molding fixation and a stretching step, and deforms thematerial such that a cross-sectional shape is a rhombic shape or thelike, a flat portion is not plastically deformed at room temperaturethrough pressure application in a sandwiched state. The manufacturingmethod is disadvantageous in that the material is not strengthened andthat the strength is likely to decrease. Additionally, if a flat portionis formed in a separate advance step, as in the conventional method, acord is likely to be twisted or bent. Thus, in a separate later step,positioning at the time of forming uneven portions at the flat portionis difficult, and working efficiently is likely to decrease extremely.

Note that although a case where the mower cord 10 is manufactured usingthe wire rod S perfectly circular in cross-section has been illustratedin the above-described embodiment, the present invention is not limitedto this. For example, the wire rod S square or rhombic in cross-sectioncan be used, as shown in FIGS. 9(A) and 9(B). In this case, pressure isapplied on one pair of diagonal portions K1 of the wire rod S while thediagonal portions K1 are engaged with the grooves 222 and 232 of the die210, thereby plastically deforming the other diagonal portions K2 withthe pressing surfaces 224 and 234. In this manner, the flat portions 14can be constructed.

Although a case where the grooves 222 and 232 are V-shaped incross-section has been illustrated in the embodiment, the presentinvention is not limited to this. For example, cross-sections of thegrooves 222 and 232 may each have the shape of a perfect circular arc oran elliptical arc, as shown in FIGS. 9(C) and 9(D). In this case, thewire rod S that has the shape of a perfect circle in cross-section, theshape of an ellipse in cross-section, or the like is preferably used. Ifthe curvatures of the grooves 222 and 232 are made smaller than that ofthe wire rod S, contact points, contact lines, or contact surfaces, atwhich the grooves 222 and 232 are to come into contact with the wire rodS, are at the center in the width direction of the wire rod S. Ifpressure is applied on the wire rod S at the contact points, the contactlines, or the contact surfaces, the wire rod S is pushed and spread inthe pressure-application perpendicular direction Y. Thus, part of thewire rod S spreads from the grooves 222 and 232 toward outer sides inthe pressure-application perpendicular direction Y to constitute theflat portions 14.

Although a case where the flat portions 14 expanding in thepressure-application perpendicular direction Y are constructed byplastically deforming the wire rod S with the pressing surfaces 224 and234 has been illustrated in the embodiment, the present invention is notlimited to this. For example, flat portions 15 expanding in thepressure-application direction X can be constructed by forming inadvance slits 222S and 232S extending in the pressure-applicationdirection X at deepest portions of the grooves 222 and 232 V-shaped incross-section and letting part of a material flow into the slits 222Sand 232S at the time of applying pressure on the wire rod S, as shown inFIGS. 10(A) and 10(B).

Although a case where the flat portions 14 are constructed by formingthe pressing surfaces 224 and 234 on the outer sides of the grooves 222and 232 and plastically deforming the wire rod S with the pressingsurfaces 224 and 234 has been illustrated in the embodiment, the presentinvention is not limited to this. For example, the wire rod S can bemade rhombic in cross-section by making the maximum widths Mw in thepressure-application perpendicular direction Y of the grooves 222 and232 V-shaped in cross-section larger than the wire rod S in advance andapplying pressure on the wire rod S in a sandwiched state with thegrooves 222 and 232 themselves, as shown in FIGS. 10(C) and 10(D). As aresult, the flat portions 15 formed by flattening the wire rod S in thepressure-application direction X can be constructed, as compared withthe wire rod S before the pressure application in a sandwiched state.Additionally, the flat portions 15 may be defined as extended portionswhich are formed by pushing and spreading the wire rod S having thedimension Sw in the pressure-application perpendicular direction Ybefore the pressure application in a sandwiched state toward the outersides in the pressure-application perpendicular direction Y by Mk. Theuneven portion 16 may be formed at the flat portions 15 by the punches240.

Although a case (see FIG. 3) where the plastic-working region 210A andthe trimming region 210B are separately provided in the die 210 has beenillustrated in the embodiment, the present invention is not limited tothis. For example, the punches 240 and punches 241 may be installed inthe first pressure die 220 and the second pressure die 230, and distalend surfaces 240A and 241A of the punches 240 and 241 may double as partof the pressing surfaces 224 and 234 that plastically deform the wirerod S, as shown in FIG. 11(A). In this case, the flat portions 14 areformed by crushing the wire rod S with the distal end surfaces 240A and241A of the punches 240 and 241. Subsequently, the flat portions 14 aretrimmed by moving the punches 240 and 241, as shown in FIG. 11(B). Inthis manner, the uneven portions 16 can be formed. As a result, aplastic-working region and a trimming region are provided in the sameplace in the die 210.

For example, cutter blades 248 which follow distal end shapes of theuneven portions 16 are formed in advance on at least one of the firstpressure die 220 and the second pressure die 230, as shown in FIG. 12.The cutter blades 248 can trim the uneven portions 16 at the same timeas plastic deformation under pressure.

Although a case where the flat portions 14 of the mower cord 10 aretrimmed to form the uneven portions 16 in the trimming step (step S109)has been illustrated in the embodiment, the present invention is notlimited to this. For example, side walls 250 which follow the shapes ofdistal ends (ridges) of the uneven portions of the mower cord 10 areprepared in advance in the die 210, and the shape of an edge in a widthdirection of each of the pressing surfaces 224 and 234 of the firstpressure die 220 and the second pressure die 230 is made to coincidewith the shape of the corresponding distal end (ridge) of the unevenportions of the mower cord 10, as shown in FIG. 13. In this state, thefirst pressure die 220 and the second pressure die 230 are moved alongthe side walls 250. With this movement, spaces surrounded by thepressing surfaces 224 and 234 and the side walls 250 have the shapes ofthe flat portions 14 with the uneven portions 16, as shown in FIGS.14(A) to 14(C) and FIGS. 14(D) to 14(F). The uneven portions 16 can besimultaneously formed through plastic deformation.

For example, as in the die 210 shown in FIGS. 15 and 16, the pressingsurfaces 224 and 234 that are convex toward an inner side (i.e., towardthe wire rod S) in the pressure-application perpendicular direction Ymay be constructed. In this case, part of the wire rod S is plasticallydeformed so as to be pinched by bringing only the pressing surfaces 224and 234 closer to each other while holding the wire rod S with thegrooves 222 and 232 formed in the first pressure die 220 and the secondpressure die 230. As a result, the part of the wire rod S is pushed andspread toward the outer sides in the pressure-application perpendiculardirection Y, thereby forming the flat portions 14 convex toward theouter sides in the pressure-application perpendicular direction Y, asshown in FIG. 16. The flat portion 14 is repeatedly formed along alongitudinal direction of the wire rod S to form a plurality of flatportions 14. With the shapes of the flat portions 14, the unevenportions 16 that are continuous in the longitudinal direction aresimultaneously completed (see FIG. 5).

Although a case in FIG. 1 where the shape of the uneven portion 16 is anarcuate shape convex toward an inner side has been illustrated in theembodiment, various shapes can be selected as the shape of the unevenportion 16. For example, the shape of the uneven portion 16 may be ashape with continuous V-shaped mountains or valleys or a saw bladeshape, as shown in FIG. 17(A), or may be an arcuate shape convex towardan outer side, as shown in FIG. 17(B). In this case, working may beperformed such that the main body portion 12 includes part of the unevenportion 16, as shown in FIG. 17(C).

Although a case where the uneven portions 16 are formed in a directionchanging the width in the pressure-application perpendicular direction Yof the flat portion 14 has been illustrated in the embodiment, thepresent invention is not limited to this. For example, the unevenportions 16 may be formed by plastically deforming each flat portion 14such that the flat portion 14 is displaced in the pressure-applicationdirection X, as shown in FIG. 18.

Note that although a case where the plastic-working region 210A and thetrimming region 210B are integrally constructed in one die has beenillustrated in the embodiment, separate machines (dies) may be used forworking.

Although a case where the trimming step is performed after theplastic-working step has been illustrated in the embodiment, the presentinvention is not limited to this. For example, the trimming step may beperformed earlier so as to form uneven portions at an element wire, andthe uneven portions may be subjected to the plastic-working step laterto be stretched in a diametrical direction.

The present invention is not limited to the above-described embodiment,and various modifications may be made without departing from the spiritand technical ideas thereof.

The invention claimed is:
 1. A manufacturing method for a mower cord,comprising: extruding a resin raw material and molding the resin rawmaterial into a resin rod having a longitudinal axis; after the moldingis complete, pressing the molded resin rod between a pair of opposedpressing surfaces of a pressure die which approach the molded resin rodin a direction perpendicular to the longitudinal axis and plasticallydeforming by cold working at room temperature at least part of themolded resin rod in a direction perpendicular to the longitudinal axis;wherein: the pressure die includes a pair of opposed side walls orientedtransversely to the pressing surfaces and each having an uneven shape;the pressing surfaces having outer edges shaped to conform with theuneven shapes of the side walls; a site where the at least part of themolded resin rod is cold-worked has a flat portion which is thinner thanthe molded resin rod before the pressing; the flat portion protrudesoutwardly in a radial direction of the molded resin rod; a plurality ofuneven portions which are continuous in a longitudinal direction of themolded resin rod are formed at the flat portion by the side walls suchthat outer distal edges of the uneven portions conform to the unevenshapes of the side walls; the flat portion and the uneven portions areformed simultaneously by the cold working; and the pressing is carriedout by moving the opposed pressing surfaces relative to the side wallsin a pressing direction perpendicular to the longitudinal axis of themolded resin rod.
 2. The manufacturing method for the mower cordaccording to claim 1, wherein a cross-sectional shape of the moldedresin rod is changed to an imperfect circular shape by the cold working.3. The manufacturing method for the mower cord according to claim 1,wherein the flat portion is thinner, as measured in a directioncorresponding to the pressing direction, than a thickness of the moldedresin rod before the pressing.
 4. The manufacturing method for the mowercord according to claim 1, wherein the outer distal edges of the unevenportions form ridges which extend in the longitudinal direction of themolded resin rod.
 5. The manufacturing method for the mower cordaccording to claim 1, further including stretching the resin rawmaterial.
 6. The manufacturing method for the mower cord according toclaim 1, wherein a cross-section in the direction perpendicular to thelongitudinal axis of the molded resin rod has any one of a circularshape, an elliptical shape, a rectangular shape, and a rhombic shape. 7.The manufacturing method for the mower cord according to claim 1,wherein the pressure die includes a pair of opposed pressure dies whichrespectively define the opposed pressing surfaces, the opposed pressuredies being movable towards one another and relative to the side walls tosandwich the molded resin rod between the opposed pressing surfaces. 8.The manufacturing method for the mower cord according to claim 7,wherein: at least one of the pressure dies has a groove which stores themolded resin rod; and the molded resin rod is pressed while being heldin place by the groove.
 9. The manufacturing method for the mower cordaccording to claim 8, wherein the pressing surface of the one pressuredie defines at least part of the groove and comes into contact with themolded resin rod.
 10. The manufacturing method for the mower cordaccording to claim 8, wherein: the one pressure die has a pair of outerpressing surfaces disposed at opposite sides of the groove, each outerpressing surface extending towards an adjacent one of the side walls ina direction perpendicular to the longitudinal axis and forming part ofthe pressing surface of the one pressure die, the outer edges of thepressing surface of the one pressure die being disposed at respectiveterminal outer ends of the outer pressing surfaces of the one pressuredie disposed immediately adjacent the respective side walls; and themolded resin rod is pressed by the outer pressing surfaces while beingheld by the groove to form the flat portion.
 11. The manufacturingmethod for the mower cord according to claim 7, wherein at least one ofthe pressure dies has a tapered surface which comes into contact withthe molded resin rod.
 12. The manufacturing method for the mower cordaccording to claim 1, wherein the pressing and cold working causesaccumulation of internal strain in the flat portion.
 13. Themanufacturing method for the mower cord according to claim 1, furthercomprising sandwiching the molded resin rod between the opposed pressingsurfaces and between the side walls to simultaneously form the flatportion and the uneven portions by the cold working.
 14. Themanufacturing method for the mower cord according to claim 1, whereinthe uneven shapes of the respective side walls of the pressure die andthe uneven shapes of the outer edges of the pressing surfaces compriselongitudinally extending undulations.
 15. A method of manufacturing amower cord, said method comprising the steps of: forming a solid resinrod from a resin raw material, the solid resin rod having a longitudinalaxis; thereafter pressing the solid resin rod between a pair of opposedpressing surfaces of a pressure die which are movable in a pressingdirection perpendicular to the longitudinal axis and plasticallydeforming by cold working at room temperature part of the solid resinrod in a direction perpendicular to the longitudinal axis to form a flatportion that is thinner than the solid resin rod before the step ofpressing and cold working, the flat portion protruding outwardly in aradial direction of the solid resin rod; wherein the step of pressingand cold working, simultaneously with forming the flat portion, forms aplurality of uneven portions along the flat portion with opposed anduneven side walls of the pressure die such that the plurality of unevenportions extend continuously in the longitudinal direction of the solidresin rod and such that outermost edges of the uneven portions conformto the opposed and uneven side walls, wherein outer edges of thepressing surfaces disposed immediately adjacent the respective sidewalls have shapes which respectively conform thereto; and wherein thestep of pressing and cold working includes moving the opposed pressingsurfaces towards the solid resin rod and along and relative to the sidewalls.
 16. The manufacturing method according to claim 15, wherein thepressure die includes a pair of pressure dies which respectively definethe opposed pressing surfaces and which pressure dies are movabletowards one another to sandwich the molded resin rod between the opposedpressing surfaces.
 17. The manufacturing method for the mower cordaccording to claim 15, wherein the step of pressing and cold workingincludes sandwiching the molded resin rod between the pressing surfacesand between the side walls to simultaneously form the flat portion andthe uneven portions.